Variable-volume insulated shipping container

ABSTRACT

A variable-volume shipping container has both cushioning and insulating characteristics, so that it may be used to ship items which are fragile, or items which require refrigeration, or both. The container includes an expansible volume-varying element which expands in thickness while maintaining its plan-view shape after the container is closed and secured, so that fragile items are held snugly, or so that items needing refrigeration are held in good heat transfer relation to a refrigerant, such as dry ice, placed into the container along with the items to be shipped. Methods of making expansible volume-varying elements of various configurations and having a differing number of expansible elements are disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to shipping containers, and moreparticularly relates to a variable-volume insulated shipping container.The shipping container can advantageously be used both for shippingfragile items which possibly are of irregular shape, and for shippingperishable products which require cooling or refrigeration duringtransport. The container has an external protective and shape-retaining(or rigid) receptacle, which may be defined by a crate or cardboard box,for example; and an internal insulative and volume-varying structure.The volume varying structure may receive the item(s) to be shipped,possibly along with a quantity of refrigerant, such as dry ice.Immediately before the outer container or receptacle is close, provisionis made for the volume-varying structure to expand in thickness whilesubstantially retaining its plan-view shape, thus filling all availableullage volume within the outer container. During shipping of thecontainer, as the volume of the dry ice decreases, the volume-varyingstructure continues to expand insuring close contact of the dry ice withthe item(s) being shipped.

2. Related Technology

Traditionally, containers for shipping temperature sensitive productshave generally included conventional cardboard shipping containershaving an insulating material therein. The insulating material may besimple loose-fill Styrofoam “peanuts,” for example, in which a chunk ofdry ice is placed along with the material to be shipped. Another varietyof conventional insulated shipping container utilized panels orcontainers made of an insulating material, such as expanded polystyrene(EPS). EPS is a relatively inexpensive insulating material, and it maybe easily formed into a desired shape, has acceptable thermal insulatingproperties for many shipping needs, and may be encapsulated or facedwith protective materials, such as plastic film or metal foil, orplastic film/metal foil laminates.

Containers including EPS are often provided in a modular form.Individual panels of EPS insulation, possibly wrapped in foil or thelike, are preformed using conventional methods, typically with bevelededges. The panels are then inserted into a conventional cardboard boxtype of shipping container, one panel against each wall, to create aninsulated cavity within the container. In this arrangement, the bevelededges of adjacent panels form seams at the comers of the container. Aproduct is placed in the cavity and a plug, such as a thick polyether orpolyester foam pad, is placed over the top of the product before thecontainer is closed and prepared for shipping. In many cases, a coolant,such as packaged ice, gel packs, or loose dry ice, is placed around theproduct in the cavity to refrigerate the product during shipping.

Alternatively, an insulated body may be injection molded from expandedpolystyrene, forming a cavity therein and having an open top to accessthe cavity. A product is placed in the cavity, typically along withcoolant, and a cover is placed over the open end, such as the foam plugdescribed above or a cover formed from EPS.

For shipping items which are particularly sensitive to temperature(i.e., temperature which is either too high or too low), such as certainmedical or pharmaceutical products, expanded rigid polyurethanecontainers are often used, as expanded polyurethane has thermalproperties generally superior to EPS. Typically, a cardboard containeris provided having a box liner therein, defining a desired insulationspace between the liner and the container. Polyurethane foam is injectedinto the insulation space, substantially filling the space and generallyadhering to the container and the liner. The interior of the box linerprovides a cavity into which a product and coolant may be placed. A foamplug may be placed over the product, or a lid may be formed fromexpanded polyurethane, typically having a flat or possibly an invertedtop-hat shape.

For shipping particularly fragile objects, objects which have anirregular shape, or items which are particularly sensitive totemperature (i.e., temperature which is either too high or too low),conventional shipping containers are frequently found to be less thanoptimum. That is, the fact that the product and coolant are typicallyplaced together within the cavity in the container, may have severaladverse effects. When shipping certain products, it may be desired torefrigerate but not freeze the product. Placing a coolant, such as looseblocks of dry ice, into the cavity against the product may inadvertentlyfreeze and damage the product. Even if held away from the product, thecoolant may shift in the cavity during shipping, especially as it meltsand shrinks in size, inadvertently contacting the product.

Accordingly, there is a need for an improved shipping container tomaintain temperature sensitive items in a determined relation to arefrigerant, such as dry ice. There is also a need for a shippingcontainer that has particular utility for shipping fragile items ofirregular shape.

SUMMARY OF THE INVENTION

The present invention is directed generally to an improved shippingcontainer which has both volume-varying properties, and insulatingproperties, and which may be used for shipping item(s) which are ofirregular shape, or which require a temperature-controlled environmentduring shipping, or both.

One aspect of the present invention provides a plan-shape-retainingexpansible panel member usable as a volume-varying insulator or cushionfor shipping, the expansible panel member comprising: a resilient foamedpolymer panel part having cells which are at least partially open, thepanel part having a determined plan-view shape, an undeformed thicknessdimension, and edge dimensions; a shape retaining base sheet having arespective plan-view shape substantially alike in size and shape to thatof the panel part, the base sheet also having respective edge dimensionswhich approximate those of the panel part, the base sheet and panel partbeing arranged congruently to one another; a fluid impermeable filmencapsulating the base sheet and panel part and excluding ambient airfrom the cells of the panel member so that the panel part maintains adeformed thickness dimension which is a fraction of the undeformedthickness dimension; whereby, the base sheet and the panel part areplaced within the film while open to ambient air, and ambient air is atleast partially removed from the cells so that the panel part defines adeformed thickness dimension which is less than the undeformed thicknessdimension and defines a plan-view shape approximating that of the basesheet, and the film is then closed so that thereafter atmosphericpressure maintains the panel part substantially at the deformedthickness dimension until a user pierces the film to admit ambient airto the panel member.

According to another aspect, the present invention provides a method ofmaking a plan-shape-retaining expansible panel member useable as avolume-varying insulator or cushion for shipping, the panel member beingexpansible substantially only in thickness, the method comprising stepsof: providing a resilient foamed polymer panel part having cells whichare at least partially open, configuring the panel part to have adetermined shape, an undeformed thickness dimension, and edgedimensions; providing a fluid impermeable film; placing the panel partwithin the fluid impermeable film while open to ambient; providing apress having a cavity of substantially the determined shape andthickness less than the undeformed thickness; utilizing the press todeform the panel member along the thickness dimension to press outambient air at least partially from the cells so that the panel partdefines a deformed thickness dimension which is less than the undeformedthickness dimension and defines a shape approximating that of thecavity, and while maintaining the compression of the panel part closingthe film so that thereafter atmospheric pressure maintains the panelpart substantially at the deformed thickness and substantially in theshape of the cavity.

Other objects and features of the present invention will become apparentfrom consideration of the following description taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is an external perspective view of a shipping container embodyingthe present invention;

FIG. 2 is a perspective view of a three-part insulative and expansible,volume-varying element according to the present invention;

FIG. 3 is an exploded perspective view of the container seen in FIG. 1,with a pair of the three-part insulative and expansible volume-varyingelements as seen in FIG. 2 preparatory to these elements being unitedbefore an item to be shipped is in placed into the container;

FIG. 3A provides a fragmentary elevation view of an encircled portion ofFIG. 3, and illustrates an integral or “living hinge” feature of thethree-part insulative and expansible volume-varying elements;

FIGS. 4, 5, and 6 each provide a cross sectional plan view taken throughthe container of FIGS. 1 and 3, after an item to be shipped have beenclosed in the container along with a quantity of dry ice pellets, andshow the progressively decreasing volume of the dry ice and increasingvolume of the expansible volume-varying elements with the passage oftime;

FIG. 7 provides a perspective view of an alternative embodiment of anexpansible volume-varying element (which is of six-part form) accordingto this invention;

FIG. 7A provides an exploded perspective view of a shipping containerincluding an external box, and one of the alternative six-partexpansible volume-varying elements as is seen in FIG. 7 preparatory toassembly of the shipping container;

FIGS. 8, 8A, and 8B provide sequential illustrations of steps in themethod of making a single (or one-part) expansible volume-varyingelement according to the present invention; and

FIGS. 9, 9A, 9B, 9C, and 9D provide sequential illustrations of steps inthe method of making a three-part expansible volume-varying elementaccording to the present invention.

FIG. 10 provides a perspective illustration of a container as seen inFIGS. 1, 2, and 3 in its “flat” form for shipping of the containeritself to a user.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to the drawings, considering FIGS. 1-3 and 3A inconjunction, and giving attention first of all to FIG. 1, a shippingcontainer 10 in accordance with the present invention is illustrated.This shipping container 10 has shock absorbing or protectivecharacteristics. The shipping container also has insulatingcharacteristics. And still further, this container 10 has volume varyingcharacteristics (i.e., the internal volume of the container isvariable). In order to provide all of these desirable characteristics ina single container, the container 10 most preferably includes anexterior cardboard shipping container or box 12, with rigid wallsgenerally referenced 14, and including flaps (best seen in FIG. 3, andreferenced 14 a, 14 b, 14 c, and 14 d) which when open define an upperopening 16, leading to a rectangular prismatic cavity 18 within the box12. It will be understood that the bottom of the box 12 is closed byother flaps (not seen in the drawing Figures), but which areconventional in the pertinent art. Thus, the cavity 18 is of fixedvolume. It will be understood that other rigid receptacles, such as acrate made of wood, or a metal shipping box, or a trunk can be used insubstitution for the cardboard box 12.

FIG. 2 illustrates one expansible volume-varying (i.e., variable-volume)element 20 for use as part of the container 10. The element 20 has shockabsorbing protective qualities, as will be explained, has insulatingqualities, and also has volume-varying qualities. As is seen in FIG. 2,the expansible element 20 is of three-part configuration, including afirst expansible panel part 22 hingeably connected to a secondexpansible panel part 24, and hingeably connected to a third expansiblepanel part 26. The panel parts 22, 24, and 26 are sized along theirmajor dimensions to generally correspond to the wall sizes of the box12, as will be further explained. The expansible panel parts 22, 24, 26are integrally connected to one another by flexible integral webs or“living hinge” sections, indicated 28 and 30 on FIG. 2. As will be seen,the hinge sections 28, 30 also provide for a determined fluid flowcommunication among the three expansible panel parts 22, 24, and 26. Theelement 20 has a fluid-impermeable “skin” indicated on FIG. 2 with thenumeral 32. It is the skin 32 which forms the integral webs betweenpanels 22-26 for hingeably connecting together these panel parts, whilealso providing for fluid flow communication among the panel parts, aswill be further explained.

Further, it will be noted in FIG. 2 that each of the expansible panelparts 22, 24, and 26 has a certain overall thickness, which his ratherthin with respect to the side dimensions of these panel parts. Thiscertain overall thickness is a variable for the element 20, as will beexplained, so that the volume of this element 20 is also a variable. Thepanel parts 22-26 have a substantially fixed plan-view shape, and varytheir volume by expanding in the thickness dimension.

Considering FIG. 3, it can be seen that a first expansible panel element20 a can be hinged in to a Z-shape and is thus inserted into the box 12with one panel covering the floor of the box, one panel (i.e., themiddle panel) covering one side wall 14 of the box 12, and one panelhinged outwardly through the opening 16. As thus prepared, another panelelement 20 b, is hinged into a U-shaped configuration and is placed intothe box with the three panels 22, 24, 26 of this element 20 b eachcovering one of the remaining side walls 14 of the box 12. The two panelelements 20 a and 20 b need not be the same size, and in fact it iseasily understood that the sizes of the panel parts of each of theelements 20 a and 20 b will be selected in view of the sizes of thefloor, side walls, and top wall of the box 12.

As is seen in FIG. 3A for example, the panels 22, 24, and 26 of theelements 20 are each connected by a “living hinge” 28, 30 (only thehinge 28 being seen in FIG. 3A) which is in the form of a flexible webof sufficient thickness that it accommodates the hinging of the adjacentpanels 22, 24, 26 through at least 90° when the panels are in theirinitial rather thin configuration (shown in dashed lines in FIG. 3A),and even if the panels 22-26 are in a thicker configuration (i.e., ofincreased volume), as is shown by solid lines in FIG. 3A. Thiscooperative configuration of the two panel elements 20 a and 20 b asseen in FIG. 3 thus provides an interior cavity (indicated with thenumeral 34 on FIG. 3.

In order to use the shipping container of FIG. 3, item(s) 36 to beshipped is placed into the cavity 34 (attention now to FIG. 4). If theitems require refrigeration, then a quantity of dry ice pellets 38 (bestseen in FIG. 4) can be placed about the item(s). Alternatively, aquantity of Styrofoam “peanuts” may be placed about the items(s). Thesepeanuts can also be represented by the pellets 38 seen in FIG. 4. As soprepared, the cavity 34 will still have a certain amount of ullagevolume, and the items to be shipped will not be snug or “tight” with thedry ice pellets, Styrofoam peanuts, or other packing material placedinto the cavity 34 along with the items 36. It will be understoodviewing FIG. 4 that this is a plan view, but that an elevation viewwould look similar. So, an underlying bed as well a top layer of dry icepellets, Styrofoam peanuts, or other packing material is desirablyprovided in the cavity 34 all around the item(s) 36 to be shipped.Returning to a consideration of FIG. 3, it will be understood that withthe container 10 so prepared to be closed, as the top panel of element20 a is hinged into place (see arcuate arrow FIG. 3) the user of thecontainer 10 will use a pin, hobby knife, awl, or simply the point of aball point pen, for example, to effect a small puncture in the skin 32each of the elements 20 a and 20 b.

Conveniently, the element 20 b can be pierced at any place along any oneof the top edges of the panels 22-26, and the projecting panel ofelement 20 a can be folded into place and the outside surface (i.e., theskin 32) of this panel can then be pierced. Because the panels 22-26each have fluid flow communication with the other panels of the element20 a or 20 b, it does not matters where the user effects the puncturesor pierces of the elements 20 a and 20 b. The result of the puncturingof the elements 20 is that they begin to take in ambient air and start arather slow expansion in their thickness dimension. So, the user of thecontainer 10 has adequate time to close the box 12. That is, afterpiercing the elements 20 a and 20 b the user then immediately closes theflaps 14 a-d of the box 12 (i.e., before the elements 20 a and 20 bsignificantly expand), and secures these flaps—perhaps with glue ortape, providing a closed shipping container packed with contents to beshipped, as seen in FIG. 1.

As is seen in FIG. 4, the elements 20 a, 20 b, in a short time after theclosing of the container 10 expand in thickness enough to be conformalto the mass of pellets 38, and so that these pellets 38 are urged intosnug engagement with the contents 36. Although the panel elements 20 aand 20 b are resilient and conformal, they have a substantially fixed orconstant plan-view shape, as was seen in FIG. 2. In the case of items 36needing refrigeration, the resulting snug engagement of the dry iceinsures good heat transfer between the dry ice and the contents 36. Inthe case of an item 36 (possibly of irregular shape, and possiblyfragile) which is surrounded by Styrofoam peanuts or other packingmaterial, the snugness provided by the expanding elements 20 insuresthat the item(s) 36 cannot rattle or shift about within the box 12during transport. The force provided by the expansion of the expansiblepanel elements 20 is not generally sufficient to damage even the mostfragile of items which would commonly be shipped by common carrier.

Those ordinarily skilled in the pertinent arts will understand that dryice deliquesces (i.e., evaporates from a solid directly to a gas) withthe passage of time. Consequently, the mass of dry ice pellets 38 losesvolume during transport of the container 10. Accordingly, viewing FIG.5, the container 10 is shown in cross section at a time later than thatseen in FIG. 4, and at a time when the dry ice 38 has significantlydecreased in volume. However, as is seen in FIG. 5, the expansiblevolume-varying elements 20 a and 20 b have expanded in thicknesssufficiently that the remaining volume of dry ice pellets 38 is stillsnuggly urged against the items 36 being shipped in the container 10.Still later in time, viewing now FIG. 6, the container 10 is shown incross section at a time later than that seen in FIG. 5, and much laterthan the time shown in FIG. 4, and at a time when the dry ice 38 hasdecreased in volume so that only a small fraction of its original volumeremains. But, as is seen in FIG. 6, the expansible volume-varyingelements 20 a and 20 b have expanded in thickness even more, andsufficiently so that the small remaining volume of dry ice pellets 38 isstill held against the items 36 being shipped in the container 10. Inthis way, continued refrigeration or cooling of the contents 36 isensured during transit of the container 10 to its destination.

In view of the above, it will be appreciated that the expansiblevolume-varying elements 20 a and 20 b have an initial volume that is inthe range from about 10% to about 25% of their final expanded volume.This change in volume of the expansible panel members 20 a and 20 b iseffected rather slowly over a period of time, and is initiated by a userof the container 10 by piercing or puncturing the elements 20 so as toallow ambient air and gases to enter into the panels through the skin32. The expansible volume-varying elements 20 a and 20 b have asubstantially fixed plan-view shape and increase in volume by increasingin thickness. Shortly after the box 12 of container 10 is closed,expansion of the thickness of elements 20 a and 20 b will havesubstantially eliminated all ullage volume within the box 12.

Turning now to FIGS. 7 and 7A, an alternative embodiment (i.e., secondembodiment) of the present inventive insulated shipping container isillustrated. Because this second embodiment shares many features andstructures in common with the first embodiment described above, thesefeatures are indicated on FIGS. 7 and 7A with the same numeral usedabove, and increased by one-hundred (100). Viewing FIGS. 7 and 7A inconjunction, it is seen that an insulated shipping container 110 inaccordance with the present invention includes an exterior cardboardshipping container or box 112, with walls generally referenced 114, andincluding flaps (best seen in FIG. 7A, and referenced 114 a, 114 b, 114c, and 114 d) which when open define an upper opening 116, leading to arectangular prismatic cavity 118 within the box 112. It will beunderstood that the bottom of the box 112 is closed by other flaps (notseen in the drawing Figures), but which are conventional in thepertinent art. The cavity 118 is of fixed volume. FIG. 7 illustrates amulti-part or multi-panel (but unitary or integral) expansiblevolume-varying element 120. This volume varying element 120 includes 6expansible panel portions 122-132, These expansible panel portions122-132 of the volume-varying elements 120 are hingeably connected byrespective flexible web or “living hinge” sections 134-142. The panels122-132 have a fluid impermeable skin 144, and this skin forms the hingesections 134-142 while also providing for fluid flow communication amongthe panel members 122-132.

As FIG. 7A illustrates, the expansible volume-varying panel element 120is sized and configured to be folded into an open wall structure 120 aseen in preparation to this wall structure being inserted into thecavity 118 of box 112. As inserted into the cavity 118, the wallstructure forms its own cavity 134 within the box 112. Within the cavity134, contents to be shipped may be inserted along with a quantity of dryice pellets (if refrigeration is needed) or along with a quantity ofStyrofoam “peanuts” or other packing material (if refrigeration is notneeded). The panel 132 is then closed over the packed cavity 134, and aperforation or piercing is formed in the element 120 by the user of thecontainer 110. Then, immediately, the flaps 114 a-d of the box 112 areclosed and secured. As before, the expansible panel portions 122-132 ina short time expand such that all ullage volume within the box 112 iseliminated.

FIGS. 8, 8A, and 8B provide sequential illustrations of steps in amethod of making a single (or one-part) expansible volume-varyingelement 146 (shown completed in FIG. 8B) according to the presentinvention. In other words, the embodiment of FIGS. 8-8B includes only asingle expansible panel portion. Considering first FIG. 8, it is seenthat a flexible but shape-retaining base sheet 148 is provided. Thisbase sheet 146 will preferably have edge dimensions selected toapproximate the size of a wall of a box within which the panel 146 willbe used (recalling the description above). The base sheet 148 may bemade of a number of materials which provide acceptable physicalcharacteristics. For example, a plastic base sheet of polyethylene ofabout 15 to 40 mils thickness may be used. However, the Applicant hasdetermined that the most economical material for use as base sheet 148is paperboard. Because paperboard may be had commercially in a varietyof thicknesses, weights, and stiffnesses, and at very low costs, it is asimple matter to identify a low-cost, functionally effective materialfor use in making the base sheet 148.

Atop of the base sheet 148, a block, sheet, or panel 150 of foammaterial having substantially the same edge dimensions as the base sheet148 is received. Most preferably, the foam material 150 is open cell (orat least partially open-cell) resilient foamed polymer material. Anumber of foamed polymer materials are available and are acceptable foruse in the panel 150. FIG. 8A shows that the combination of base sheet148 and foam block 150 are received into a bag 152 of polymer filmmaterial. A number of polymer film or sheet materials are availablewhich are acceptable for making the bag 152. A particularly effectivematerial is a nylon film sheet, similar to that which is used to makeimpermeable bags for fumigation. Other polyester or polyether, orpolyolefin, bags materials, such a polyethylene and polypropylene filmsare available. The bag 152 is elongate and is sufficiently deep that itprovides a skirt portion 152 a with an opening 154 providing access tothe cavity 154 of the bag.

The base sheet 148 and foam block 150 are slid into the cavity 154 ofbag 152 so that the skirt 152 a is extending beyond the base sheet 148and foam block 150. Then, as is illustrated by opposed arrows “F” inFIG. 8A, the foam block 150 is compressed in the plane of panel 146 (butis not substantially compressed or made smaller in transverse planes).That is, the foam block is not compressed or made smaller along the edgedimensions of the base sheet 148. This compression of the foam block 150may be effected by applying vacuum to the cavity 154, for example. Whenvacuum is used to evacuate the bag 152 and effect compression of thefoam block 150, the base sheet 148 is effective to support the foammaterial in the edge directions of the base sheet, so that the foammaterial does not wrinkle or warp into saddle or “potato chip” shape.Alternatively, the assemblage of base sheet 148, foam block 150, and bag152 may be compressed along the lines indicated by the arrows “F” ofFIG. 8A by using a pair of opposed flat pressing members (not seen inFIG. 8A).

As FIG. 8B shows, after the work piece for an expansible panel 146 iscompressed to a relatively small thickness, which is a fraction of itsundeformed thickness, and while the compression is maintained (arrows“F” of FIG. 8B), the skirt 152 a of the bag 152 is heat sealed (as isindicated by the opposed arrows 156 on FIG. 8B) to create a seal line158 extending across and closing the skirt 152 a. Subsequently, theskirt 152 a is trimmed to a comparatively short length, as seen in FIG.8B, maintaining the seal line 158. It will be understood that subsequentto the steps shown by FIGS. 8, 8A, and 8B, if a user of the expansiblepanel pokes a hole in the film of bag 152, then the panel 146 willaspirate ambient air as the foam 150 expands, and the panel 146 willexpand toward its full thickness. During this expansion, the foammaterial will expand on the side away from the base sheet 146, so it isdesirable that a user of the expansible panel 146 place the base sheettoward a wall of a box, and the foam side of the expansible panel 146toward the items to be shipped. In the case of a transparent film beingused to make bag 152, the user will be able to easily see which side ofthe panel member 146 to place toward the items being shipped. On theother hand, if a film is used to make bag 152 which is not transparent,then the panel member 146 can be marked during manufacture to indicatewhich side a user is to place toward items to be shipped.

FIGS. 9, and 9A through 9D illustrate steps in the method of making athree-part, or three panel, expansible volume-varying element, such asthe elements 20 a or 20 b seen in FIG. 3. Viewing first FIG. 9, it isseen that similarly to the embodiment illustrated in FIGS. 8-8B, theexpansible panel element will include foam blocks or panels, eachindicated with the arrowed numeral 200. These foam blocks or panels 200,however, in the embodiment of FIGS. 9-9D do not need to be supported ona base sheet, such as the base sheet 148 referred to with respect toFIGS. 8-8B. However, the foam blocks or panels 200 are received into aplastic bag 202, which is this instance is deep enough to accept threeof the foam blocks 250 in spaced apart arrangement. The plastic bag 202includes an elongate skirt 202 a, as is seen best in FIG. 9. The bag 202defines a cavity 204.

FIG. 9A illustrates that the three foam blocks 200 in plastic bag 202are placed into a pressing apparatus, generally indicated with arrowednumeral 206. But, FIGS. 9 and 9B illustrate that in preparation for thestep of FIG. 9A, the bag 202 is heat sealed, as indicated by arrows 208to form an interrupted heat seal line (indicated by numeral 210)adjacent to each of the foam blocks 200. Thus, a web 212 (i.e.,recalling hinge portions 28 and 30 seen in FIG. 2) is defined betweeneach adjacent pair of the foam blocks 200. Because the heat seal lines210 is interrupted, fluid flow passages (indicated by connecting arrows214 on FIG. 9B) are defined within the webs 212. It will be seen thatFIG. 9 illustrates the bag 202 both in its initial condition with theblocks 200 inserted and spaced apart, and in its condition after thewebs 212 (i.e., hinge portions 28, 30—recalling FIG. 2 once again) areformed

Returning to consideration of FIG. 9A, it is seen that the pressingapparatus includes a base portion 216 including a peripheral flange orwall portion 218. Similarly, the pressing apparatus 206 includes a lidportion 220 also including a peripheral flange or wall portion 222. Thebase portion 216 and lid portion 220 are hingeably connected by hinges224, so that the lid 220 may be closed on and be congruent with the baseportion, as is indicated with arcuate arrow 226, viewing FIG. 9A. Itwill be understood that when the lid 220 is closed on base 216, adetermined separation between these two items is maintained by theirrespective flanges 218 and 222 abutting one another, so that asubstantially closed cavity 228 of determined thickness is formed. As isseen in FIG. 9A, the skirt 202 a of the bag 202 is extended outwardlyfrom the pressing apparatus 206 before the lid 220 is closed. With thework piece for the expansible panel element prepared according to theillustrations of FIG. 9 and 9B, the lid 220 of the apparatus 206 isforcefully closed (arrow 226 of FIG. 9A) compressing the foam blocks 200along their thickness dimension (but not substantially causing anycompression along the edge dimension of these foam blocks) to athickness which is only a fraction of their uncompressed thickness.During this compression of the foam blocks 200 (indicated by forcearrows F on FIG. 9C), air is expelled via the extending portion of skirt202 a (as is indicated by the arrow on FIG. 9C). In order to assist withthe expulsion of air from within the bag 202 and from within the foamblocks 250, a partial vacuum may be communicated to the inside of skirt202 a seen protruding from the pressing apparatus in FIG. 9C.

Upon completion of the pressing step of FIG. 9C, and with sufficientevacuation of air from within the foam blocks 250 and from within bag202, a heat seal line 230 is formed across the protruding portion ofskirt 202 a, as is indicated by the opposed arrows 232 in FIG. 9D. Uponopening of the pressing apparatus 206, and removal of the expansiblepanel element from within the cavity 228, this panel element will appearthe same as the element 20 illustrated in FIG. 2. In view of the above,it is apparent that a differently configured pressing apparatus and alarger configuration of plastic bag may be used to manufacture thesix-part expansible panel element 120 seen in FIGS. 7 and 7A. Stillalternatively, a five-panel element similar to the element 120 seen inFIG. 7 may be made by eliminating the sixth panel portion 132. In thatcase, when the panel element is inserted into a box, the resultingcavity (i.e., like cavity 134 seen in FIG. 7A) will be open at the top.In order to close that open top before the box is closed and sealed, asingle expansible panel element such as element 146 seen in FIG. 8B, maybe utilized.

Turning now to FIG. 10 a container 10 as is seen in FIGS. 1-3 isillustrated in its “flat” form, which the container will have during itsown shipping to a user (i.e., to a store, for example, where a user willpurchase the container 10). As a contrast and comparison, it is wellunderstood that common Styrofoam coolers (i.e., ice chests, for example,made of EPS) are very bulky for manufacturers to ship to stores wherethey are kept in inventory until a user purchases them. Similarly, thestores have to devote a large storage area to these ice chests eventhough they weigh very little. That is, conventional EPS coolers and icechests are light but bulky and take up a lot of space. In contrast, theinsulated container 10 seen in FIG. 1 offers an insulating value atleast as good as the common commercial ice chest having walls about 1inch thick of EPS. Further, the container 10 may be provided with asimple handle for convenient carrying (perhaps of twine), and with aninternal plastic bag, allowing melt water to be retained. Thus, thepresent invention offers an insulated container that can be employed forall uses conventionally calling for a Styrofoam cooler or ice chest.Further, the present container allows a great savings in shipping costsand in storage requirements over conventional EPS ice chests andcoolers.

Viewing FIG. 10, it is seen that the box 12 is in its “flat condition,with the top and bottom flaps open and the walls 14 pivoted intoconjunction with one another. In this condition, a large number of suchboxes 12 may be shipped on a pallet and can be stored in a small space.Similarly, FIG. 10 shows a pair of the panel elements 20, which may beused as illustrated in FIG. 3 to provide insulation within the box 12.As is seen in FIG. 10, the pair of panel members 20 are also in their“flat” condition, and a large number of these panel members can also beshipped on a pallet and stored until they are needed. That is, as seenin FIG. 10, the panels 20 are partially evacuated and have (andmaintain) their compressed thickness which is a fraction of their fullthickness. As thus supplied to a user, the user would take one of theboxes 12, and a pair of the panel elements 20, and would also storethese components of the container 10 in their “flat” condition untilready to use the container. Then the user unfolds the box 12, and tapesor otherwise secures the bottom flaps in place. The panel elements 20are each pierced by the user allowing them to expand to their fullthickness, and they are placed into the box 12 as illustrated in FIG. 3.Then the user (if desired) places a supplied plastic bag into the cavity34 to retain melt water, possibly attaches a twine handle, and uses thecontainer as an ice chest or cooler in the normal way. Moreover, the box12 may be provided with a pair of opposite hand holes (i.e., forming apair of opposite handles on the box) to allow the box to be convenientlycarried, or it may be provided with a inexpensive twine handle allowingone-handed carrying.

While the invention is susceptible to various modifications, andalternative forms, specific examples thereof have been shown in thedrawings and are herein described in detail. It should be understood,however, that the invention is not to be limited to the particular formsdisclosed, but to the contrary, the invention is to cover allmodifications, equivalents and alternatives falling within the spiritand scope of the appended claims. For example, it is apparent that thefive or 6 panel elements seen in FIG. 7 may be manufactured with a webspanning between and connecting the panels 122-130 (rather than havingthat web trimmed as is seen in FIG. 7). An advantage of the embodimentin which the web is not trimmed (in addition to eliminating themanufacturing cost of this trimming step) is that in a use to containrefrigeration within a container, the refrigerated air (or carbondioxide in the case of deliquescing dry ice) is cold and tends to rundown and out of a container much as water would run out. In the case ofcarbon dioxide this phenomenon is even more pronounced because of thedensity of the carbon dioxide being higher than air. With the connectingwebs intact, when the panel element is formed into the open wallstructure seen in FIG. 7A, the connecting webs between the panelportions 122-130 form an effective “basin” which would hold water, andwhich will likewise retain cold air or cold carbon dioxide. This “basin”effect assists in retaining the cold air or gas within the container 10,and prolongs the refrigeration effect that may be obtained from aquantity of dry ice or other refrigerant. It is also clear in view ofthe above, that the single panel expansible element as shown in FIG. 8B,for example, may be rolled into the shape of a tube, and then may beutilized within a cardboard shipping tube, for example, to receive itemsto be shipped.

1. A plan-shape-retaining expansible panel member usable as avolume-varying insulator or cushion for shipping, said expansible panelmember comprising: a resilient foamed polymer panel part having cellswhich are at least partially open, said panel part having a determinedplan-view shape, an undeformed thickness dimension, and edge dimensions;a shape retaining base sheet having a respective plan-view shapesubstantially alike in size and shape to that of said panel part, saidbase sheet also having respective edge dimensions which approximatethose of said panel part, said base sheet and panel part being arrangedcongruently to one another; a fluid impermeable film encapsulating saidbase sheet and panel part and excluding ambient air from said cells ofsaid panel member so that said panel part maintains a deformed thicknessdimension which is a fraction of said undeformed thickness dimension;whereby, said base sheet and said panel part are placed within said filmwhile open to ambient air, and ambient air is at least partially removedfrom said cells so that said panel part defines a deformed thicknessdimension which is less than said undeformed thickness dimension anddefines a plan-view shape approximating that of said base sheet, andsaid film is then closed so that thereafter atmospheric pressuremaintains said panel part substantially at said deformed thicknessdimension until a user pierces said film to admit ambient air to saidpanel member.
 2. The expansible panel member of claim 1 wherein saidplan-view shape is rectangular.
 3. A plan-shape-retaining expansiblepanel member for usable as an insulator or cushion for shipping, saidexpansible panel member comprising: a resilient foamed polymer panelpart having cells which are at least partially open, said panel parthaving a determined plan-view shape, an undeformed thickness dimension,and edge dimensions; a fluid impermeable film encapsulating said panelpart and excluding ambient air from said cells of said panel member sothat said panel part maintains a deformed thickness dimension which is afraction of said undeformed thickness dimension; whereby, said panelpart is placed within said-film while open and within a press having acavity of substantially said determined shape, and said press isutilized to press ambient air at least partially from said cells so thatsaid panel part defines a deformed thickness dimension which is lessthan said undeformed thickness dimension and defines a shapeapproximating that of said cavity, and said film is then closed so thatthereafter atmospheric pressure maintains said panel part substantiallyat said deformed thickness and substantially in the shape of said cavityuntil a user pierces said film to admit ambient air to said panelmember.
 4. The expansible panel member of claim 3 wherein said plan-viewshape is rectangular.
 5. A method of making a plan-shape-retainingexpansible panel member useable as a volume-varying insulator or cushionfor shipping, said panel member being expansible substantially only inthickness, said method comprising steps of: providing a resilient foamedpolymer panel part having cells which are at least partially open,configuring said panel part to have a determined shape, an undeformedthickness dimension, and edge dimensions; providing a fluid impermeablefilm; placing said panel part within said fluid impermeable film whileopen to ambient; providing a press having a cavity of substantially saiddetermined shape and thickness less than said undeformed thickness;utilizing said press to deform said panel member along said thicknessdimension to press out ambient air at least partially from said cells sothat said panel part defines a deformed thickness dimension which isless than said undeformed thickness dimension and defines a shapeapproximating that of said cavity, and while maintaining saidcompression of said panel part closing said film so that thereafteratmospheric pressure maintains said panel part substantially at saiddeformed thickness and substantially in the shape of said cavity.
 6. Amulti-part, plan-shape-retaining expansible panel element, saidexpansible panel element which is expansible in thickness, said panelelement comprising: plural resilient foamed polymer panel parts eachhaving cells which are at least partially open, each of said pluralpanel parts having a respective determined plan-view shape, anundeformed thickness dimension, and edge dimensions; a fluid impermeablefilm encapsulating said plural panel parts and excluding ambient airfrom said cells of said panel parts, said fluid impermeable film alsoproviding a flexible web extending between adjacent panel parts, andproviding both for hinging of said panel parts relative to one anotherby flexing of said web and for fluid flow communication between adjacentpanel parts within said web; whereby, said plural panel parts arepartially evacuated within said film so that each panel part defines adeformed thickness dimension which is less than said undeformedthickness dimension and defines a shape approximating said respectivedetermined plan-view shape, so that atmospheric pressure maintains saidpanel parts substantially at said deformed thickness until a userpierces said film to admit ambient air to said panel element, andthereafter said webs provide for air to flow among said plural panelparts to allow expansion toward said undeformed thickness dimension. 7.Apparatus for use in making a partially evacuated expansible panelmember having an undeformed thickness, and a deformed thickness which isless than said undeformed thickness, said panel member having adetermined plan-view shape and edge dimensions which are substantiallyconstant, said panel member including a resilient open-cell foam polymerpanel part substantially of undeformed thickness, and an enclosing filmof air-impermeable material preventing ambient air from entering saidpanel element so that atmospheric pressure maintains said panel part atsaid deformed thickness, said pressing apparatus-comprising: a basemember and a lid in relatively movable juxtaposition to one another andin a closed position cooperatively defining a cavity substantiallymatching said determined plan-view shape and a thickness substantiallymatching said deformed thickness; forcing means for moving said basemember and lid into said closed position; heat sealing apparatusdisposed relative to said base member and lid, and disposed to heat sealan extending skirt portion of a bag made of said film and containingsaid panel part within said closed cavity;
 8. A shipping container, saidshipping container comprising: an outer shape-retaining enclosureincluding rigid walls defining a fixed-volume cavity and an opening tosaid fixed-volume cavity, said shape-retaining container including arigid lid for closing said opening; plural expansible volume-varyingpanel members received in said cavity along said walls and cooperativelydefining therein a respective variable-volume cavity, each of saidplural expansible panel members comprising: a resilient foamed polymerpanel part having cells which are at least partially open, said panelpart having a determined shape, an undeformed thickness dimension, andedge dimensions; a fluid impermeable film encapsulating said panel partand excluding ambient air from said cells of said panel member so thatsaid expansible panel member maintains a thickness dimension only afraction of said undeformed thickness dimension of said panel part,whereby, an item to be shipped is received in the variable-volume cavityand immediately before closing said lid a user provides an openingthrough said film allowing entry of ambient air and expansion of saidplural panel members about said item within the closed shippingcontainer.
 9. A method of making a multi-part, plan-shape-retainingexpansible panel element, said expansible panel element comprising:providing plural resilient foamed polymer panel parts each having cellswhich are at least partially open; configuring each of said plural panelparts to have a respective determined plan-view shape, an undeformedthickness dimension, and edge dimensions; providing a bag member formedof a fluid-impermeable film; encapsulating said plural panel parts inspaced apart relation within said bag member; forming a web portion ofsaid bag member extending between adjacent ones of said spaced apartpanel parts, and configuring said web portion to provide at least onefluid flow passage providing for gas flow between said adjacent ones ofsaid panel parts, and also providing for said flexible web to flex andeffect hinging of said panel parts relative to one another; at leastpartially removing ambient air from said cells of said plural panelparts while reducing the thickness dimension of said panel parts to adeformed dimension less that said undeformed dimension and maintainingtheir plan view size and shape substantially constant; sealing said bagand employing said fluid-impermeable film to exclude entry of ambientair to said panel parts, and utilizing atmospheric pressure to maintainsaid panel parts at said deformed thickness dimension. whereby, saidplural panel parts are partially evacuated within said film so that eachpanel part defines a deformed thickness dimension which is less thansaid undeformed thickness dimension and defines a shape approximatingsaid respective determined plan-view shape, so that atmospheric pressuremaintains said panel parts substantially at said deformed thicknessuntil a user pierces said film to admit ambient air to said panelelement, and thereafter said webs provide for air to flow among saidplural panel parts to allow expansion toward said undeformed thicknessdimension.